AFP Manufacturing Engineer II-Composites

Firefly Aerospace, Inc.; Texas; On-site; USD 90,000 - 130,000; Full time

Benefits offered by this job

Unlimited PTO

3‑month sabbatical every 5 years

Medical, dental, vision, life, and A/D

Mental health services

Paid military leave

12 weeks maternity leave

Educational reimbursement

Stock bonuses and 401(k)

Job summary

Firefly Aerospace, Inc. in Austin, Texas is seeking an Automated Fiber Placement (AFP) Manufacturing Engineer II – Composites to lead development and optimization of AFP ply programs for aerospace parts.

You will work with Ingersoll Gen2 systems, Vericut simulation tools, and cross‑functional teams to improve part quality, reduce cycle times, and support production start‑ups. The role requires a bachelor's degree in mechanical/aerospace engineering, 5+ years in carbon fiber aerospace

Qualifications

• Bachelor's degree in Mechanical Engineering or related field.
• 5+ years in carbon fiber composite aerospace manufacturing.
• AFP experience and automated fiber placement expertise.
• Experience with AFP programming and machine optimization.
• CAD software proficiency and AFP programming familiarity.
• Proven ability to drive process improvements and cost reductions.
• Strong communication and cross-functional collaboration skills.
• Ability to thrive in a fast-paced aerospace environment.

Responsibilities

• Oversee AFP ply program development for composite parts using Ingersoll Gen2 and Vericut tools.
• Translate ply books and lamination schedules into executable AFP paths with correct fiber orientation.
• Support machine setup, calibration, and laser alignment for production.
• Analyze and optimize machine pathing to reduce defects and increase efficiency.
• Validate AFP programs via simulations and dry runs with operators.
• Provide DFM feedback to design for manufacturability of AFP parts.
• Investigate and resolve AFP-related issues with cross-functional teams.
• Develop and maintain standard work instructions and AFP best practices.
• Contribute to tooling design reviews and process documentation.

Skills

AFP experience

Carbon fiber composites

CAD software

AFP programming

Process improvements

Cross-functional collaboration

Communication skills

Problem solving

Self-motivation

Aerospace manufacturing

Education

Bachelor's degree in Mechanical Engineering or related field

Aerospace/mechanical engineering background

Tools

Ingersoll Gen2

Vericut AFP programming

Job description

At Firefly, we’re focused on making space attainable for everyone – including you! Each team member’s passion, dedication, and innovative ideas have a direct impact on fueling our successful trajectory into space. And there’s no shortage of meaningful projects to work on at Firefly. With launch, lunar, and orbital vehicles, Firefly has a diverse line of business with opportunities to get hands‑on experience launching rockets, operating in space, and landing on the Moon.

Our Values

Headquartered in the Lone Star State, Firefly’s hardworking team reflects Texas’ GO BIG culture in everything we do. We build big, achieve big, and dream big. We’re building launch vehicles and spacecraft to provide rapid, reliable space access. We’ve achieved some incredible wins, including the first successful commercial Moon landing. And we’re dreaming bigger than this planet with ambitions to Mars, Venus, and beyond. Our core values are what drive us along the way.

Passion

Fireflies believe in perseverance, responsiveness, and mentoring others with a focus on inspiring a better future.

Accountability

Fireflies act with integrity and take ownership of our actions, commitments, decisions, and outcomes.

Fireflies work in alignment across teams and communicate clearly with mutual respect for one another.

Fireflies deliver high-quality work through technical rigor and timely disciplined execution for our customers.

We take care of our Fireflies with some of the best benefits in the industry. Our mission to make space for everyone starts with our employees and allowing them to make space for their family, their career, and their future.

Space for You

• Unlimited PTO for exempt employees
• 3-month sabbatical for every 5 years of service
• Medical, dental, vision, life, and disability insurance
• Mental health services
• Paid military leave

Space for Your Family

• 12 weeks paid maternity leave
• 4 weeks paid spouse leave
• $20k towards family planning: fertility, surrogacy, adoption
• Dog friendly workplace

Space for Your Career

• $10k/year towards trade school or college
• Ongoing coaching to advance leadership skills
• Employee-ownership with stock bonuses
• 4% Safe Harbor 401(k) matching
• $10k bonus for home purchase in Cedar Park, Texas

Job Openings

From launch technicians to propulsion engineers, Firefly has open roles across the company. We’re looking for passionate, bright innovators to join our team and help make space an achievable dream for everyone.

AFP Manufacturing Engineer II-Composites

Firefly Aerospace is a space and defense technology company that enables our world to launch, land, and operate in space – anywhere, anytime. As the partner of choice for critical space missions, Firefly is the only commercial company to launch a satellite to orbit with 24-hour notice and the only company to achieve a successful Moon landing. Our launch vehicles, lunar landers, and orbital vehicles provide government and commercial customers with full mission services from low Earth orbit to the Moon and beyond. Headquartered in north Austin, Texas, Firefly is looking for passionate, hardworking innovators to join our team and help fuel our successful trajectory into space.

SUMMARY

The Automated Fiber Placement (AFP) Engineer is responsible for the development, and optimization of automated composite layup processes and overseeing the AFP programming process using Ingersoll AFP systems. This role supports production and engineering by generating precise ply programs, improving part quality, reducing cycle time, and troubleshooting AFP-related issues in the manufacture of complex aerospace components. The AFP Engineer works closely with design engineering, NC programming, operations, quality, and maintenance teams.

The following essential job functions are performed as an Automated Fiber Placement Engineer:

RESPONSIBILITIES

• Oversee the development AFP ply programs for composite parts using Ingersoll Gen2, (VCP) Vericut Composite Programming, and (VCS) Vericut Composite Simulation programming tools and simulation software, ensuring conformance to design intent and manufacturing constraints
• Translate engineering models, ply books, and lamination schedules into executable AFP paths with accurate fiber orientation, coverage, and boundaries
• Support Ingersoll machine setup, calibration, and laser alignment for first article and repeatable production runs
• Analyze and optimize machine pathing to minimize defects (e.g., gaps, overlaps, tow steering errors), improve machine efficiency, and extend tool life
• Review and validate AFP programs with simulations and dry runs, working alongside operators during production start-ups
• Collaborate with design engineering to provide design for manufacturability (DFM) feedback for composite parts intended for AFP
• Investigate and resolve machine and process-related issues, working cross-functionally with maintenance and Ingersoll technical support as needed
• Participate in tooling design reviews to ensure compatibility with AFP head dimensions, access, and laser projection systems
• Implement and document process improvements, material usage reductions, and automation enhancements
• Work with facilities team to enhance critical spares documentation and write PM plans.
• Develop and maintain standard work instructions, AFP best practices, and process documentation
• Support audits, root cause investigations, and corrective actions involving AFP-manufactured parts
• Maintains composure under pressure while successfully managing multiple deadlines
• Being at work on time and maintaining good attendance is a condition of employment and is an essential function of the job
• Must have excellent communication skills, both verbal and written in the English language

QUALIFICATIONS

Required

• Bachelor's degree in Mechanical Engineering or a related Engineering field.
• 5 years experience in carbon fiber composite aerospace manufacturing
• Strong technical aptitude and ability to quickly become an expert on complex hardware.
• Automated Fiber Placement experience
• Experience with interrogating machine efficiency and implementing process improvements to reduce time and waste.
• Proficiency in CAD software and AFP Programming.
• Excellent communication skills and ability to collaborate effectively with cross-functional teams.
• Demonstrated track record of driving process improvements and delivering results in a fast-paced environment.
• High level of initiative, self-motivation, and ability to thrive in a dynamic and challenging work environment.
• Excellent problem-solving and analytical abilities.
• 5+ years working in a aerospace manufacturing or engineering environment with a bachelor’s degree in mechanical, aerospace, or similar area.
• Experience with capital equipment implementation.
• Master's degree is a plus.
• Six Sigma or Lean manufacturing Black Belt certification

Primary Level Salary Range:

Firefly offers outstanding benefits for our employees, including generous health, dental and vision plans with low plan deductibles, parental leave, relocation benefits, educational reimbursement, short term disability, and flexible PTO options.

To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.

Firefly Aerospace, Inc. is an Equal Opportunity Employer; employment with Firefly is governed based on merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.